k-system isolated barriers - pepperl+fuchs

ISO9001

K-System

Isolated Barriers

Manual

With regard to the supply of products, the current issue of the following document is applicable:The General Terms of Delivery for Products and Services of the Electrical Industry, published by the Central Association of the Electrical Industry (Zentralverband Elektrotechnik und Elektroindustrie (ZVEI) e.V.) in its most recent version as well as the supplementary clause: "Expanded reservation of proprietorship"

WorldwidePepperl+Fuchs GroupLilienthalstr. 20068307 MannheimGermanyPhone: +49 621 776 - 0E-mail: [email protected] American Headquarters Pepperl+Fuchs Inc.1600 Enterprise ParkwayTwinsburg, Ohio 44087USAPhone: +1 330 425-3555E-mail: [email protected] Headquarters Pepperl+Fuchs Pte. Ltd.P+F Building18 Ayer Rajah CrescentSingapore 139942Phone: +65 6779-9091E-mail: [email protected]://www.pepperl-fuchs.com

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K-System – Isolated BarriersContents

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1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.1 Content of this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.2 Target Group, Personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.3 Symbols Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Product Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.2 Housing Styles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.3 Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112.4 Color Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.5 Status Indicators of the Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162.6 Operating Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172.7 Label Carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192.8 DIN Mounting Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192.9 Power Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3 Mounting and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213.1 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213.2 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365.1 Fault Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365.2 Fault Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375.3 Current and Voltage Standard Signals . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6 Dismounting, Maintenance, and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406.1 Dismounting the Isolated Barrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

7 Technical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427.2 Model Number Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457.3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

K-System – Isolated BarriersContents

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K-System – Isolated BarriersIntroduction

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1 Introduction

1.1 Content of this DocumentThis document contains information that you need in order to use your product throughout the applicable stages of the product life cycle. These can include the following:

• Product identification• Delivery, transport, and storage• Mounting and installation• Commissioning and operation• Maintenance and repair• Troubleshooting• Dismounting• Disposal

The documentation consists of the following parts:• Present document• Instruction manual• Datasheet

Additionally, the following parts may belong to the documentation, if applicable:• EU-type examination certificate• EU declaration of conformity• Attestation of conformity• Certificates• Control drawings• Additional documents

NoteThis document does not substitute the instruction manual.

NoteFor full information on the product, refer to the instruction manual and further documentation on the Internet at www.pepperl-fuchs.com.

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K-System – Isolated BarriersIntroduction

1.2 Target Group, PersonnelResponsibility for planning, assembly, commissioning, operation, maintenance, and dismounting lies with the plant operator.Only appropriately trained and qualified personnel may carry out mounting, installation, commissioning, operation, maintenance, and dismounting of the product. The personnel must have read and understood the instruction manual and the further documentation.Prior to using the product make yourself familiar with it. Read the document carefully.

1.3 Symbols UsedThis document contains symbols for the identification of warning messages and of informative messages.

Warning MessagesYou will find warning messages, whenever dangers may arise from your actions. It is mandatory that you observe these warning messages for your personal safety and in order to avoid property damage.Depending on the risk level, the warning messages are displayed in descending order as follows:

Informative Symbols

ActionThis symbol indicates a paragraph with instructions. You are prompted to perform an action or a sequence of actions.

Danger!This symbol indicates an imminent danger.Non-observance will result in personal injury or death.

Warning!This symbol indicates a possible fault or danger.Non-observance may cause personal injury or serious property damage.

Caution!This symbol indicates a possible fault.Non-observance could interrupt the device and any connected systems and plants, or result in their complete failure.

NoteThis symbol brings important information to your attention.

K-System – Isolated BarriersProduct Specifications

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2 Product Specifications

2.1 FunctionIsolated barriers are isolators used for protection of intrinsically safe circuits in hazardous areas. In addition to the required current, voltage and power limitation, the isolated barriers have a galvanic isolation between the field circuit and the controller.

Figure 2.1 Function – isolating, amplifying and transforming signalsThe K-System consists of wide range of isolated barriers suitable for mounting on 35 mm DIN mounting rail. K-System is easy to specify, integrate and expand. Our extensive line of intrinsic safe isolators for hazardous location applications contains over 150 different devices.

Figure 2.2 K-System on Power Rail

Control system

Sensor

Actuator

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2.2 Housing StylesDepending on the functionality and application, K-System devices have 3 different housing widths:

• KC devices with 12.5 mm width• KF devices with 20 mm width• KF devices or KH devices with 40 mm width

The 3 housing widths versions have the same system characteristics. All devices can be mounted on the 35 mm DIN mounting rail or the Power Rail. See chapter 2.9

KC Device Housing

Figure 2.3 KC device housing (12.5 mm)Used for high signal integrity

• Compact 12.5 mm housing• High packing density with single loop integrity

PWR

1

3

4

II

2S

OUT/CHK

I

KCD2-SR-Ex1.LB

2

4

1

3

9 10

8

6

7

5


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KF Device Housing

Figure 2.4 KF device housing (20 mm)Used for high channel density

• Compact 20 mm housing• Packing density from 5 mm per channel

Figure 2.5 KF device housing (40 mm)Used for applications with high functionality

• Digital devices monitor speed, direction of rotation, slip, flow rates and time.• Analog devices monitor transmitter signals, temperature signals and load cells.• Configured using keypad or PACTwareTM software, see also manual "Installation

and Configuration Device Type Manager (DTM)"• AC/DC wide range supply available

KFD2-ER-Ex1.W.LB

1 34 6

25

13 15129

107

14118

OUT CHK PWR

sens.

ESC

OK

KFD2-WAC2-Ex1.D

RS232

PWR

1 2FLT

OUT

19 21159

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20148

22 241812

1610

231711

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KH Device Housing

Figure 2.6 KH device housing (40 mm)

10 11 12

16 17 18

4 5 6

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7 8 9

13 14 15

1 2 3

19 20 21

1CHKPWROUT

KHA6-SH-Ex1

S


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2.3 Terminals

2.3.1 Removable Terminal BlocksThe removable terminal blocks simplify connection and control cabinet assembly. The terminal blocks offer space for the connection of leads with core cross-sections of up to 2.5 mm2 (14 AWG). The terminal blocks are coded with red coding pins so misconnection of terminal blocks are eliminated.Observe the tightening torque of the terminal screws. The tightening torque is 0.5 Nm to 0.6 Nm.The 20 mm and 40 mm wide KF devices are factory-equipped with screw terminals. The KC devices are available with screw terminals or spring terminals. The order designation of the versions of the KC devices with spring terminals has the extension ".SP".As an alternative to the factory-equipped terminal blocks the devices can be used with other terminal blocks:

• Terminal blocks with screw terminals• Terminal blocks with screw terminals and test plug socket• Terminal blocks with spring terminals and test plug socket

These terminal blocks are available as accessories. The terminal blocks can be easily coded with KF-CP coding pins (available optionally).

Figure 2.7 K-System removable terminal blocks

1 Terminal blocks with screw terminals2 Terminal blocks with screw terminals and test sockets3 Terminal blocks with spring terminals and test sockets

129

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Protection against direct contactThe removable terminal blocks have different heights:

• Height 15 mm (1), (2), (3): These terminal blocks are used in applications that have rated voltages lower than 50 V AC. The insulation of the removable terminal blocks provides protection against direct contact. The insulation corresponds to a reinforced insulation according to EN 61010-1 for a rated insulation voltage of 50 V AC.

• Height 15.5 mm (4), (5): These terminal blocks are used in applications that have rated voltages higher than 50 V AC. The insulation of the removable terminal blocks provides protection against direct contact. The insulation corresponds to a basic insulation according to EN 61010-1 for a rated insulation voltage of 300 V AC. The higher terminals are marked (X).

Figure 2.8 Removable terminal blocks with different heights

1 Terminal block with screw terminals, height 15 mm2 Terminal block with screw terminals and test sockets, height 15 mm3 Terminal block with spring terminals and test sockets, height 15 mm4 Terminal block with screw terminals and test sockets, height 15.5 mm5 Terminal block with screw terminals, height 15.5 mmX Marking

15.115.115.1

15

15.110.1

15

.5

1 52 3 4

X

NoteSee corresponding datasheets for further information.


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2.3.2 Terminal Designation

Figure 2.9 KC device housing (12.5 mm)

Figure 2.10 KF device housing (20 mm)

NoteSee corresponding datasheets for precise terminal designation.

9 10

8

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7

5

2

4

1

3

3 4

1 2

7 8

5 6

9 10

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7 8 9

10 11 12

13 14 15

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Figure 2.11 KF device housing (40 mm)

Figure 2.12 KH device housing (40 mm)

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1 32 4 65

1 2 3

7 8 9

13 14 15

19 20 21

4 5 6

10 11 12

16 17 18

22 23 24

10 11 12

16 17 18

4 5 6

22 23 24

7 8 9

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1 2 3

19 20 21


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2.4 Color IdentificationThe color identification of the devices has the following meaning:

• Green (1) indicates devices with DC power supply.• Black (2) indicates devices with AC power supply.• Gray (3) indicates devices with AC/DC wide range supply.• Blue (4) indicates devices that process signals from the hazardous area.

Figure 2.13 Color identification of devices

1 green2 black3 gray4 blue

ESC

OK

KFU8-UFT-Ex2.D

RS232

PWR1

1 2

3

2

4

IN/CHK

OUT

19 21159

137

20148

22 241812

1610

231711

1 32 4 65

KFD2-ER-Ex1.W.LB

1 34 6

25

13 15129

107

14118

OUT CHK PWR

sens.

KFA5-ER-Ex1.W.LB

1 34 6

25

13 15129

107

14118

OUT CHK PWR

sens.

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4

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2.5 Status Indicators of the IsolatorsLEDs are often used on isolators to indicate different statuses (e. g. for power supply, device failure, status messages, binary switching states). Standard LED colors are assigned to the status display according to NAMUR NE44.

Figure 2.14 Example status indicators

LED Display function Display MeaningGreen LED Power supply On Power supply OK

Off No power supply or insufficient power supply – device faulty

Red LED Device fault, device failure

On Internal fault signal, failure signal – fault/failure display of causes detected inside the device, device needs replacing

Line fault Flashing External fault signal, failure signal – fault/failure display of causes detected outside the device, inspection and elimination of fault required

No fault Off No malfunction, device is operating properlyYellow LED Switching states of

binary inputs and outputs

On Possible causes of the output:• The relay is energized.• The NO contact (also a change-over contact)

is actively closed.• The open collector is switched through.• The switching voltage generated inside the device

is applied.Possible causes of the input:• A binary switching signal is present.• An analog limit value is reached.

Off Possible causes of the output:• The relay is de-energized.• The NO contact (also a change-over contact)

is actively opened.• The open collector is not switched through.• The switching voltage generated inside the device

is not applied.Possible causes of the input:• A binary switching signal is present.• An analog limit value is reached.

Table 2.1 Meaning of status indicators

1 Yellow LED "OUT"Switching state of the output

2 Red LED "CHK"Lead breakage and short circuit status indicator

3 Green LED "PWR"Power supply status indicator

OUT CHK PWR

1 2 3


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2.6 Operating ElementsMany devices of the K-System can be adapted to different applications. Depending on the device different operating elements are available for this configuration.These operating elements are:DIP switchesVia DIP switches you can configure the basic functions of the device.

Figure 2.15

Rotary switchesVia rotary switches you can configure the basic functions of the device.

Figure 2.16

PotentiometersVia potentiometers you can configure the calibration of input and output characteristics.

Figure 2.17

1 DIP switch

1 Rotary switch

1 Potentiometer

S2S1

S3

III

1

S2123

0

45

987 6

1

SPAN

ZERO

1

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Keypad and LC displayVia keypad you can configure the settings of the device parameters. Measured values, fault signals and configuration settings are displayed on the LC display.

Figure 2.18

Programming sockets for the connection of a PC with parameterization software PACTwareTM

Via parameterization software PACTwareTM you can configure the device easily. The configuration data can be edited and saved. The parameterization software helps users for maintenance, diagnostics and troubleshooting.

Figure 2.19

1 LC display2 Keypad

1 Programming socket

ESC

OK

21

PROGRAM

1

NoteSee manual "HART Multiplexer System KFD*-HM*-16" for further information for communication via software.



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2.7 Label CarrierFor individual labeling, the isolated barriers are equipped ex works with a label carrier. Labels can be inserted into the label carrier.It is also possible to attach an adhesive label to the transparent front flap.

Figure 2.20 Devices with transparent front flap

2.8 DIN Mounting RailThe devices are mounted on a 35 mm DIN mounting rail according to EN 60715.

Figure 2.21 Example: DIN mounting rail UPR-MR (35 mm x 15 mm)

1 Label carrier on KC devices with label 22 mm x 9 mm2 Label carrier on KF devices for with 22 mm x 16.5 mm3 Adhesive label 22 mm x 11 mm for all KC and KF devices, can only be used on devices

with a transparent front flap4 Label carrier on KF devices with label 18 mm x 8 mm, can only be used on devices

without a transparent front flap

21 2 3 4

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2.9 Power RailTo reduce wiring and installation costs, Power Rail is the optimum solution. The Power Rail is a DIN mounting rail with plastic insert, that delivers power to the devices (24 V DC) and transfers bus signals and a collective error message.The Power Rail is factory-equipped with cover and end caps. These parts cover empty and open segments of the Power Rail. Thus, the Power Rail is protected from contamination. Additionally the cover and end caps prevent that electrically conductive parts come in contact with the Power Rail.Power Rail is available in two versions:

Power Rail UPR-03The Power Rail UPR–03 has 3 conductors.

• 2 conductors for power• 1 conductor for collective error messaging

Power Rail UPR-05 (only for KFD2-WAC2-(Ex)1.D)The Power Rail UPR–05 has 5 conductors.

• 2 conductors for power• 1 conductor for collective error messaging• 2 conductors for serial data exchange

Figure 2.22 Example: Power Rail UPR-03

1 Cover UPR-COVER2 Insert UPR-INS-033 DIN mounting rail UPR-MR (35 mm x 15 mm)4 End cap UPR-E

1

2

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K-System – Isolated BarriersMounting and Installation

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3 Mounting and Installation

3.1 Mounting

Danger!Explosion hazard from damaged electronic components Premature wear of electronic components in a device that was previously used in a general electrical installation can cause sparks that can ignite the surrounding potentially explosive atmosphere.Never install devices that have already been operated in general electrical installations in electrical installations used in combination with hazardous areas!

Danger!Explosion hazard from pollutionAn excessively polluted surface of the device can become conductive and consequently ignite a surrounding potentially explosive atmosphere.Ensure that you install the device only in environments with a pollution degree 2 or better according to IEC/EN 60664–1.

Danger!Danger to life from electric shockAbsent or insufficient insulation can result in electric shock.Only connect supplies that provide protection against electric shock to power feed modules (e. g. SELV or PELV).

Caution!Property damage from use of isolators for Power Rail supplyUsing the isolators for Power Rail supply can damage the isolators and make the Power Rail fail.Do not supply the Power Rail via isolators.

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Mounting in the Non-Hazardous AreaMounting the Isolated BarrierSnap the device onto the DIN mounting rail in a vertical downward movement. See following figure.

Mounting in Areas that Require the Equipment Protection Level Gc

Mounting the Isolated BarrierSnap the device onto the DIN mounting rail in a vertical downward movement. See following figure.

Danger!Explosion hazard from live wiring of non-intrinsically safe circuitsIf you connect or disconnect energized non-intrinsically safe circuits in a potentially explosive atmosphere, sparks can ignite the surrounding atmosphere.Only connect or disconnect energized non-intrinsically safe circuits in the absence of a potentially explosive atmosphere.

Danger!Explosion hazard from wrong mountingThe device safety can be impaired by external environmental influences and by mechanical stress. That can lead to sparking that can ignite a surrounding potentially explosive atmosphere.Mount the device in a surrounding enclosure that complies with IEC/EN 60079–0 and that is rated with the degree of protection IP54 according to IEC/EN 60529.

CORRECT: Device snapped on vertically. INCORRECT: Device snapped on from the side.Can damage the contacts and cause the device to fail.

Figure 3.1

�


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Vertical and horizontal mountingLow heat dissipation allows vertical or horizontal mounting without separation distance. Operation is guaranteed over the full temperature range of the system in any mounting direction and without restriction.

Figure 3.2 Vertical mounting without separation distance (group mounting)

Figure 3.3 Horizontal mounting without separation distance (group mounting)

13

46

2 51

34

62 5

13

46

2 51

34

62 5

13129

107

1415

118

13129

107

1415

118

13129

107

1415

118

13129

107

1415

118

1 34 6

25

1 34 6

25

1 34 6

25

1 34 6

25

13129

107

14 15118

13129

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14 15118

13129

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14 15118

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14 15118

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Mounting Conditions for Operating the Device at Higher Ambient TemperatureCertain devices with a maximum allowable ambient temperature of 60 °C (140 °F) can be operated at ambient temperatures up to 70 °C (158 °F) if mounted horizontally. These devices have a corresponding reference to this manual in the datasheet.

Mounting the Isolated Barriers with Separation DistanceMount the device on the DIN mounting rail. Observe the specified minimum separation distance. See following figures.

• KC devices with 12.7 mm housing width, housing type A*: min. 6 mm• KF devices with 20 mm housing width, housing type B*: min. 10 mm• KF devices with 40 mm housing width, housing type C*: min. 15 mm

Figure 3.4 Horizontal mounting of KC devices with 12.7 mm housing width (single device mounting)

Caution!Device failure due to overlooking heat dissipationOverlooking heat dissipation can compromise the function and the electrical safety of the device.

• Mount the device on the DIN mounting rail in a horizontal mounting position.• Mount the device on the DIN mounting rail according to the specified minimum

separation distance.• Do not operate devices without this reference in the datasheet at an ambient temperature

up to 70 °C (158 °F).

12.7 ≥6 12.7 ≥6


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Figure 3.5 Horizontal mounting of KF devices with 20 mm housing width (single device mounting)

Figure 3.6 Horizontal mounting of KF devices with 40 mm housing width (single device mounting)

13129

107

14 15118

13129

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14 15118

13129

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14 15118

1 34 6

25

1 34 6

25

1 34 6

25

20 ≥10 20 ≥10

40 ≥15 40 ≥15

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Mounting the Terminal Blocks

1. Switch off the voltage.

2. Connect the terminal blocks or disconnect the terminal blocks.

3.2 Connection

Danger!Danger to life from electric shockWorking on live parts at voltages higher than 50 V AC or 120 V DC can result in electric shock.

1. De-energize the device.2. Secure the circuit against reconnection.3. Verify that the device is de-energized at all poles.4. Provide protection from adjacent live parts, if present.


Danger!Danger to life from electric shockAbsent or insufficient insulation can result in electric shock.

• Maintain sufficient distance between the connection lines, terminals, surrounding enclosure, and the environment.

• Insulate connection lines, terminals, and the surrounding enclosure from the environment.

Danger!Danger to life from incorrect installationIncorrect installation of cables and connection lines can compromise the function and the electrical safety of the device.

• Observe the permissible core cross section of the conductor.• When using stranded conductors, crimp wire end ferrules on the conductor ends.• Use only one conductor per terminal.• When installing the conductors the insulation must reach up to the terminal.• Observe the tightening torque of the terminal screws.


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3.2.1 Field Side Connection

Connecting the Field SideConnect the field devices via the screw terminals or spring terminals.

Danger!Explosion hazard from exposed conductorsExposed conductors of inadequately attached cables can cause sparks that can ignite the surrounding potentially explosive atmosphere.When installing the device ensure that the cables are adequately attached.

Caution!Property damage from use of inappropriate toolUsing an inappropriate tool may damage the screw heads.

• Use a slot-head screwdriver with a size of 3.5 x 0.5.• Observe the tightening torque of the terminal screws. The tightening torque

is 0.5 Nm to 0.6 Nm.


Danger!Explosion hazard from wrong separation distancesIf you do not observe the minimum separation distance between 2 intrinsically safe circuits, this can lead to added currents or voltages. This can result in a current/voltage flashover generating sparks. The sparks can ignite the surrounding potentially explosive atmosphere.Ensure that you observe all separation distances between 2 adjacent intrinsically safe circuits according to IEC/EN 60079-14.

Danger!Explosion hazard from wrong separation distancesIf you do not observe the minimum separation distances between intrinsically safe circuits of associated apparatus and non-intrinsically safe circuits, this can lead to added currents or voltages. This can result in a current/voltage flashover generating sparks. The sparks can ignite the surrounding potentially explosive atmosphere.Ensure that you observe the compliance of the separation distances to all non–intrinsically safe circuits according to IEC/EN 60079–14.

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3.2.2 Control Side Connection

Connection of Devices with Relay Output

Connection of other Devices

Connecting the Control SideConnect the control system via the screw terminals or spring terminals.



Warning!Risk of short circuitLive working can cause injuries to the operator and/or damage to the device.Disconnect the device, before you plug or unplug the plugs.

Danger!Danger to life from electric shockAbsent or insufficient insulation can result in electric shock.Only connect circuits that provide protection against electric shock (e. g. SELV or PELV).

Warning!Risk of short circuitLive working can cause injuries to the operator and/or damage to the device.Disconnect the device, before you plug or unplug the plugs.


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3.2.3 Power Supply ConnectionThe devices are available with different supply voltages.

• 24 V DC power supply• 115 V AC or 230 V AC power supply for applications where direct current is not available• AC/DC wide range supply with 24 V DC or 115/230 V AC

The devices are supplied with power in various ways.• Power supply without Power Rail, see chapter 3.2.3.1• Power supply with Power Rail, see chapter 3.2.3.2

• Non-redundant supply with power feed module• Redundant supply with power feed module• Direct supply with power supply

3.2.3.1 Power Supply without Power RailIf devices with AC or universal power supplies are used, the advantages of Power Rail are not available.Conventional power supplies create complicated and expensive wiring systems. After all isolated barriers are connected, there is a significant amount of wiring and more wiring must be added for extra functions such as line fault detection.

Connection of KCD and KFD Devices

Connection of KFA, KFU, and KHA Devices

Connecting the Power SupplyConnect the power supply via the screw terminals or spring terminals.

NoteThe supported supply voltage for each device is identified on the side plate.

Danger!Danger to life from electric shockAbsent or insufficient insulation can result in electric shock.Only connect supplies that provide protection against electric shock (e. g. SELV or PELV).



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Figure 3.7 Conventional installation

3.2.3.2 Power Supply with Power RailFor devices with a 24 V DC supply voltage, use of the Power Rail reduces wiring and installation costs. The Power Rail almost completely eliminates the risk of wiring faults and facilitates expansion.Power is supplied to the Power Rail via a power feed module which provides a voltage of 24 V DC (max. 4 A) to a maximum of 80 devices.The power feed module features a replaceable 5 A fuse at the front. This fuse ensures that the Power Rail and connecting contacts are protected. It prevents damage caused by reverse supply voltage or by installing too many isolators. The isolators on the Power Rail feature integrated device fuses. Any faults in the isolator or in the signal leads do not affect the Power Rail supply system. The 5 A fuse permits a rated current of up to 4 A across the entire temperature range.The power feed module also has the task of outputting a collective error message or power failure of the isolators via a separate relay output.Alternatively, supply of the Power Rail can be provided using the power supply KFA6-STR-1.24.*. In this case, no collective error message is possible.

1 DIN mounting rail

1 34 6

25

1 34 6

25

1 34 6

25

1 34 6

25

13129

107

14 15118

13129

107

14 15118

13129

107

14 15118

13129

107

14 15118

1

24 V DC


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Supply with Power Feed Module

Connecting the Power SupplyConnect the power supply via the Power Rail.

Non-Redundant SupplyThe power feed module mounts on the Power Rail for easy and reliable distribution of power to all connected isolators. This method eliminates the wiring loops (daisy chain) necessary on a conventional installation without Power Rail.

Figure 3.8 Power Rail installation

Danger!Danger to life from electric shockAbsent or insufficient insulation can result in electric shock.Only connect supplies that provide protection against electric shock to power feed modules (e. g. SELV or PELV).

Caution!Property damage from use of isolators for Power Rail supplyUsing the isolators for Power Rail supply can damage the isolators and make the Power Rail fail.Do not supply the Power Rail via isolators.

1 Replaceable fuse2 Power feed module3 Power Rail

1 34 6

25

1 34 6

25

1 34 6

25

1 34 6

25

13129

107

14 15118

13129

107

14 15118

13129

107

14 15118

13129

107

14 15118

1 34 6

25

13129

107

14 15118

32

24 V DC

1

202

1-03

32


Redundant SupplyTwo power supplies or a redundant power supply with two power feed modules offer a high degree of availability. If a power supply or the fuse in a power feed module fails, the redundant supply continues to energize the isolators through their Power Rail connection.

Figure 3.9 Redundant power connections

1 Replaceable fuse2 Power feed module 13 Power feed module 24 Power Rail

1 34 6

25

13129

107

14 15118

1 34 6

25

13 15129

107

14118

1 34 6

25

1 34 6

25

13129

107

14 15118

13129

107

14 15118

42 3

24 V DC 24 V DC

1


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Direct Supply with Power SupplyA complete power solution for a K-System installation is possible by using the following power supplies:

• KFA6-STR-1.24.4 from 115/230 V AC to 24 V DC/4 A or• KFA6-STR-1.24.500 from 115/230 V AC to 24 V DC/500 mA

The power supplies snap on the Power Rail to easily and efficiently distribute power to the isolated barriers.

Figure 3.10 Integrated power supply (4 A)

Figure 3.11 Integrated power supply (500 mA)

1 Power supply2 Power Rail

1 Power supply2 Power Rail

1 34 6

25

1 34 6

25

13129

107

14 15118

13129

107

14 15118

21

115/230 V AC

24 V DC

1 34 6

25

1 34 6

25

13129

107

14 15118

13129

107

14 15118

PWR

1 34 6

25

13 15129

107

14118

1

115/230 V AC

2

24 V DC

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34


3.2.4 Establishing the Communication via Software

Establishing the Communication via SoftwareEstablish the HART communication via K-ADP-USB adapter and HART multiplexer on the control side, if available.

Danger!Explosion hazard from sparking when plugging or pulling the adapterPlugging or pulling the adapter in a potentially explosive atmosphere can cause sparks that can ignite the surrounding atmosphere.Only plug or pull the adapter in the absence of a potentially explosive atmosphere.

Caution!Fault in the plantChanging the device data changes the device function.Before entering new device data, make sure the plant is not endangered by changing the device data.

NoteSee manual "HART Multiplexer System KFD*-HM*-16" for further information for communication via software.

K-System – Isolated BarriersConfiguration

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4 Configuration

Configuring the DeviceSet the particular operating elements as described in section "Configuration" of the data sheet.

Danger!Explosion hazard from sparking when using operating elementsUsing operating elements in a potentially explosive atmosphere can cause sparks that can ignite the surrounding atmosphere. Only use operating elements (e. g., switch, slider, button, etc.) in the absence of a potentially explosive atmosphere.

Caution!Potential device malfunction from change of device functionChanges in the device function can lead to device malfunction. The function of the device is no longer guaranteed.Before transferring the new device function, make sure that the changed device function does not cause a danger to the device and the plant.


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K-System – Isolated BarriersOperation

5 Operation

5.1 Fault MonitoringNumerous faults can occur between measurement of the process variable and evaluation in the control system. This can lead to undesirable process statuses under certain circumstances. These process statuses may result in plant downtime or quality problems or even present a hazard to persons and the environment. Depending on the device version, the isolators enable monitoring of the following faults:

• Line faultsHere, the connection cables between the isolator, the field device and the control system are monitored for lead breakages or short circuits.

• Device faultsThe isolators are designed so that internal faults are detected and reported. In the case of a power failure, the outputs are switched to the de-energized state.


Danger!Explosion hazard from sparking when using operating elementsUsing operating elements in a potentially explosive atmosphere can cause sparks that can ignite the surrounding atmosphere. Only use operating elements (e. g., switch, slider, button, etc.) in the absence of a potentially explosive atmosphere.


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5.2 Fault OutputDepending on the configuration of the devices, these faults are transmitted to the outputs at the control side and in separate fault indication outputs as additional information.

• Red fault indication LEDs on the isolator• Fault indication output• Collective error message on Power Rail

Fault Indication OutputLine and device faults are transmitted if the device has a fault indication output (FAULT). The fault indication output is active in a normal state and inactive in a fault state (closed-circuit principle). Is it impossible to reverse the detection direction of the fault indication output.

Figure 5.1

Line Fault Transparency (LFT)Line fault transparency makes electrical conditions on the field side visible on the control side of the isolator. This enables line faults between the isolator and the field device to be detected and transmitted to the control system via the signal line.

Figure 5.2 Example of line fault transparency with digital input

2-

1+ 7

8 (+/-)

FAULT101112

2+

1+7+

9-

FAULT

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38


Collective Error Message on Power RailThe fault can also be output via the Power Rail as a collective error message (FAULT).

Figure 5.3The collective error message enables line fault detection of many isolators without requiring additional wiring. In the event of a fault, a fault message signal is transmitted to the Power Rail from an isolator. The power feed module evaluates the signal and transmits the fault message signal to the controller by means of a potential-free contact.The potential-free contact simultaneously reports the device power failure or the failure of one device minimum.

Figure 5.4 Collective error message via power feed module

1 Power feed module2 Fault indication on one of the devices (red LED flashes)3 Process control system4 Fault indication output

24 V DC

Power Rail

24 V DCFAULT

1 34 6

25

1 34 6

25

1 34 6

25

1 34 6

25

13129

107

14 15118

13129

107

14 15118

13129

107

14 15118

13129

107

14 15118

1 34 6

25

13 15129

107

14118

24 V DC

1

4

3

2


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5.3 Current and Voltage Standard SignalsThe following signals have established themselves as the standard:

• the 0/4 mA to 20 mA current signal• the 0/2 V to 10 V voltage signal• the 0/1 V to 5 V voltage signal

Analog sensor signals and digital frequency signals are converted into one of the two standard signals for processing in a wide variety of measurement, regulatory and control tasks. This offers the measurement and control technician an easy-to-measure standard signal common to all manufacturers. Sensor signals are converted into standard signals via signal converters.For more diagnostic options, the NAMUR organization published NAMUR recommendation NE43, dividing the value range of the signal (e. g. current signal) into several areas. Valid, defined measurement value information is transferred within the range from 3.8 mA to 20.5 mA. Failure information is available when the signal current is < 3.6 mA or > 21 mA i. e. outside of the range for measured value information. The same applies to the voltage signal.

Figure 5.5 Signal ranges according to NAMUR NE43 (e. g. current signal)

1 Failure information2 Measuring information

I [mA]4 20 21

0 % 100 %

20.53.6 3.8

1 12

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K-System – Isolated BarriersDismounting, Maintenance, and Repair

6 Dismounting, Maintenance, and Repair

Disconnecting Circuits

1. Disconnect the power supply.

2. Disconnect the field circuit.

3. Disconnect the control circuit.

4. Disconnect the HART communication, if available.


Danger!Danger to life from using damaged or repaired devices.Using a defective or repaired device can compromise its function and its electrical safety.

• Do not use a damaged or polluted device.• The device must not be repaired, changed or manipulated.• If there is a defect, always replace the device with an original device from Pepperl+Fuchs.



K-System – Isolated BarriersDismounting, Maintenance, and Repair

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6.1 Dismounting the Isolated BarrierDismounting the Isolated BarrierUse for dismounting of the device a slotted screwdriver

1. Insert the screwdriver (4) into the groove of the red mounting slider (3).

2. Turn the screwdriver (4) in the groove until the red mounting slider (3) springs back.

3. Repeat these steps on the other side of the device.

4. Remove the isolator (2) from the DIN mounting rail (1).

Figure 6.1 Dismounting of the isolated barrier from the DIN mounting rail

1 35 mm DIN mounting rail2 Isolated barrier3 Mounting slider4 Slotted screwdriver

3 1

4

4

2

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42

K-System – Isolated BarriersTechnical Specifications

7 Technical Specifications

7.1 Technical Data

Electrical DataNon-Hazardous Area Signals or Control Circuit Signals

• 0/4 mA to 20 mA signal level according to NE 43• 0/2 V to 10 V signal level according to NE 43• 0/1 V to 5 V signal level according to NE 43• Current output HART compatible• Current input HART compatible• Digital output: active or passive electronic output 100 mA/30 V, short-circuit protected• Relay output 2 A, minimum load 1 mA/24 V• Logic level 24 V according to IEC 60946• Functional isolation or safe isolation according to IEC 61140 and NAMUR NE 23

Hazardous Area Signals or Signals in the Field Circuit• Transmitter power supply up to 17 V DC• Current output HART compatible• Pt100, 2-, 3-, (4)-wire technology• Resistor 0 to 400 with freely definable characteristic• Potentiometer• Thermocouples of all types, internal cold junction, external reference• Current output HART compatible• Digital input according to NAMUR EN 60947-5-6• Digital output for standard Ex-i valves, short-circuit protected

Characteristic Safety Values• MTBF: Mean Time Between Failures

ConformityGeneral

• Isolators with and without explosion protection, mostly with Ex ia IIC/Class I Div. 1, international approvals

• EMV according to• EN 61326-1• EN 61326-3-2, only for devices with SIL rating, where the data sheet mentions

this standard.If you operate the device with a DC supply voltage, you must ensure that the bridging of the 20 ms voltage interruption is realized by the power supply.

• NAMUR NE 21If you operate the device with a DC supply voltage, you must ensure that the bridging of the 20 ms voltage interruption is realized by the power supply.


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• LEDs according to NAMUR NE 44• Software according to NAMUR NE 53• Switch-on pulse suppression• K*D2 devices:

• Supply voltage 20 V DC to 30 V DC via Power Rail or supply terminals• Collective error message via Power Rail

• K*A devices:• Supply voltage 115 V/230 V AC, details see datasheet

• K*U devices:• Supply voltage 24 V DC or 115/230 V AC, details see datasheet

• Safety devices according to VDE 0660, part 209, AK according to DIN 19250Digital Inputs and Outputs according to NAMUR

• IEC/EN 60947-5-6: Low voltage switch gear and control gear – part 5 and 6: Control devices and switching elements – DC interface for proximity sensors and switch amplifiers (NAMUR), 1999

Ambient ConditionsAmbient Temperature

• -20 °C to 60 °C (-4 °F to 140 °F), exceptions see data sheets• extended ambient temperature range up to 70 °C (158 °F), necessary mounting

conditions see chapter 3.1Storage Temperature

• -40 °C to 90 °C (-40 °F to 194 °F), exceptions see data sheetsReference Conditions for Adjustment

• 20 °C (68 °F)Relative Humidity

• max. 95 % without moisture condensationVibration Resistance

• according to EN 60068-2-6, 10 Hz to 150 Hz, 1 g, high crossover frequencyShock Resistance

• according to EN 60068-2-27, 15 g, 11 ms, half-sine

Mechanical SpecificationsMounting

• Snap-on 35 mm DIN mounting rail according to EN 60715. Can be mounted horizontally or vertically, side by side.

• Panel mount: The lugs on the base of the isolator must be extended and used for mounting purposes with 3 mm screws.

• K-MS mounting base for screw attachmentHousing Material

• Polycarbonate (PC)Dimensions

• Dimension drawings please refer to chapter Dimensions.Protection Degree

• IP20 according to EN 60529

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Connection

• KH* devices: self-opening terminals for max. core diameter of 1 x 2.5 mm2 (14 AWG)• KF* and KC* devices: removable connector with integrated self opening terminals

for leads of up to a max. of 1 x 2.5 mm2 (14 AWG)• Observe the tightening torque of the terminal screws. The tightening torque

is 0.5 Nm to 0.6 Nm.Fire Protection Class

• Housing: V2 according to UL 94 standard. Unless stated otherwise all details relate to the reference conditions.

LabelingPlace for labeling on the front side:

• KC devices (12.5 mm): label 22 mm x 9 mm• KF devices (20 mm and 40 mm): label 22 mm x 16.5 mm• All KC and KF devices: adhesive label 22 mm x 11, can only be used on devices

with a transparent front flap• KF devices: label 18 mm x 8 mm, can only be used on devices without a transparent front

flap



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7.2 Model Number Description

K - - Ex .

1 System

2 Construction type

3 Type of power supply

4 Level of power supply

9 Special function,

if available

8 Number of channels

7 Isolated Barriers,

not applicable to Signal Conditioners

6 Device generation (2 to X)

5 Device function

Position 1 K K-SystemPosition 2 C Version with removable terminal blocks, 12.5 mm width

F Version with removable terminal blocks, 20 mm or 40 mm widthH Version without removable terminal blocks, 20 mm or 40 mm width

Position 3 D DC power supplyA AC power supplyU AC/DC power supply

Position 4 0 without power supply2 24 V4 100 V5 115 V6 230 V8 24 V DC or 115/230 V AC

Position 5 CC Converter for current/voltageCD Active current driverCR Transmitter power supply, current outputCRG Transmitter power supply with trip valueCS Passive current driverDU Switch amplifier, time relayDWB Overspeed/underspeed monitor, logic control unitEB Power feed moduleELD Ground fault detectionER Conductivity switch amplifierFF RS 232 repeater

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Position 5 GS Trip amplifier for current/voltageGU Universal trip amplifierGUT Temperature converter with trip valueHLC HART Loop ConverterHMM HART Multiplexer MasterHMS HART Multiplexer SlaveLGH Place holder isolatorPT Potentiometer converterRC Converter for resistorsRCI Solenoid driverRO Relay moduleRR Thermometer resistance repeaterRSH Relay module in fail-safe technologySCD SMART current driverSCS SMART current driver/repeaterSD Solenoid driver, loop poweredSH Switch amplifier in fail-safe technologySL Solenoid driver, bus poweredSLD Solenoid driver, bus and loop poweredSON Switch amplifier with NAMUR outputSOT Switch amplifier with passive, potential free transistor outputSR Switch amplifier with relay outputSRA Switch amplifier with relay output, 2:1 operation modeSRT Switch amplifier with active transistor and relay outputST Switch amplifier with active transistor outputSTC SMART transmitter power supply with current outputSTR Power supplySTV SMART transmitter power supply with voltage outputTR RTD converterTT Converter for thermocouple/mV signalUFC Universal frequency converterUFT Frequency converter with direction and synchronization monitoringUSC Universal signal converter with trip valueUT Universal temperature converterVC Converter for current/voltageVCR Transmitter power supply, repeater for current/voltageVD Solenoid driverVM Solenoid driverVR Voltage repeaterWAC Strain gauge converter


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7.3 Dimensions

7.3.1 Housing Types Isolated Barriers K-System

Figure 7.1Number of terminal blocks max. 5

• Dimension drawing with screw terminals• When using screw terminals with test sockets the device is 124 mm (4.9 in) in height.• When using spring terminals the device is 131 mm (5.16 in) in height.

Figure 7.2Number of terminal blocks maximum 4


Housing Type A2

Housing Type B1

12,7 mm

(0.5")

114 mm (4.49'')

46

mm

(1

.82

'')5

8 m

m (

2.2

8'') 1

19

mm

(4

.7'')

10

4 m

m (

4.1

'')20 mm 115 mm

==

10

7 m

m

93

mm

202

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48


Figure 7.3Number of terminal blocks maximum 5




Housing Type B2

Housing Type C1

20 mm 115 mm

46

mm

58

mm

11

9 m

m

10

4 m

m

40 mm (1.6'') 115 mm (4.5'')=

=

10

7 m

m (

4.2

1'')

93

mm

(3

.66

'')


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• Dimension drawing with screw terminals• When using screw terminals with test sockets the device is 124 mm (4.9 inch) in height.• When using spring terminals the device is 131 mm (5.16 inch) in height.



Housing Type C2

Housing Type D2

40 mm (1.6 inch) 115 mm (4.5 inch)

46

mm

(1

.82

inc

h)

58

mm

(2

.28

inc

h)

11

9 m

m (

4.7

inc

h)

10

4 m

m (

4.1

inc

h)

60 mm (2.36'') 115 mm (4.5'')

46

mm

(1

.82

'')5

8 m

m (

2.2

8'') 11

9 m

m (

4.7

'')

10

4 m

m (

4.1

'')

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Figure 7.7

Figure 7.8

Housing Type E

Housing Power Supply 4 A

115 mm (4.5'')

==

93

mm

(3

.66

'')

40 mm (1.6'')

140 mm (5.51'')88 mm (3.46'')

99 mm (3.9'')

10

3,5

mm

(4

.07

'')

PE L1 N + -

Primarily Secondary

K-System – Isolated BarriersNotes

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51

Pepperl+Fuchs QualityDownload our latest policy here:

www.pepperl-fuchs.com/quality

www.pepperl-fuchs.com© Pepperl+Fuchs · Subject to modifications

Printed in Germany / DOCT-0187V

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k-system isolated barriers - pepperl+fuchs

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